D9 & D9G Crawler S/n 66A1 to 66A3265

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1 Caterpillar Service Manual D9 & D9G Crawler S/n 66A to 66A65 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CT-S-D9 CRWLR

2 A-5 Group 0. Page SERVICE MANUAL for CATERPILLAR D9 TRACTOR SERIAL NUMBERS 66A ' 66A65 Section Engine 0- Starting Engine 0 ---" Power Transmission Units _ ' Track Roller Frame ~ Seat, Fuel Tank and Miscellaneous _ Jr rn CATERPILLAR Caterpillar, Cat and [8 are Trademarks of Caterpillar Tractor Co.

3 A-IO Group 0. Page ENGINE TABLE OF CONTENTS Section Group Index Specifications Cooling System Water Temperature Regulator Fan Group Water Pump Radiator Lubricating System A - 0 A -0 A -0 A -0 A -0 A -0 A -0 A Oil Pan.. Oil Pump A -0 A-O IBO. 90. Oil Cooler Oil Filters Fuel System Fuel Supply Equipment Fuel Injection Equipment Accessory Drive and Governor. Air Induction and Exhaust System Turbocharger (AiResearch TI4) Turbocharger (AiResearch TIB) Cylinder Heads Valves and Valve Mechanism Vibration Damper Front Support Timing Gears Pistons, Rings and Connecting Rods Cylinder Liners Main Bearings Crankshaft Flywheel and Flywheel Housing Diesel Engine Removal and Installation Electrical System A -0 A - 0 A -0 A-O A - 0 A -0 A - 0 4A -0 A - 0 A - 0 A -0 A - 0 A -0 A - 0 A -0 A -0 A - 0 A - 0 A - 0 A-O A BO

4 A-IO Group 0. Page ENGINE INDEX A F Adjustments: Cylinder Valve Fuel Injection Pump Lifter Fuel Rack Setting Governor.... Aftercooler.... Air Cleaner.. Aligning Engine Altitude Operation Bearings: Connecting Rod Main Bell, Suction Belts: Fan Generator Belt Tightener Breather, Crankcase By-pass: Fuel Oil Filter B Fan Filters: Fuel, Final Fuel, Primary Oil. Flow of Coolant Flow of Fuel Flow of Lubricating Oil Flywheel Flywheel Housing.. Front Accessory Drive Shaft Front Cover Front Support, Engine Fuel: By-pass Injection: Equipment Pumps Pump and Governor Drive Pump Housing Pump Lilter Setting Valve... Rack Setting System, Diesel Transfer Pump C Camshaft Camshaft Gear Chambers, Precombustion Cleaner, Air Cleaning: Engine Valves Pistons Clearances and Tolerances Compression Release Mechanism Connecting Rods and Bearings Coolers, Oil Cooling System Cover, Front Crankshaft Cylinder Heads Cylinder Liners D Gauge: Fuel Oil Gear: Camshaft: Drive Idler Ring, Flywheel Steering Clutch Booster Pump Timing Timing Marks Generator Generator Regulator Governor: Adjustments Drive Operation G Damper, Vibration Decelerator Drive: Front Accessory Service Meter II Guides, Valve H Engine Data Engine Removal and Installation Exhaust Manifold E Heads, Cylinder Housing: Flywheel Fuel Injection Pump Governor Timing Gear

5 Group 0. Page A-IO ENGINE INDEX Injection: Pumps Valve Inlet Manifold Release, Compression Removing Ring Ridge in Cylinder Liners Ring Gear, Flywheel Rings, Piston Rocker Arm Assemblies Rod, Connecting Lifter Setting, Fuel Injection Pump Lifters, Valve Liners, Cylinder.. Lubricating System Lubrication: Piston and Ring Timing Gear Main Bearings Manifold, Exhaust Manifold, Inlet Meter, Service L M Sealed Pressure Overflow Seals: Cylinder Liner Turbocharger Service Meter Setting Fuel Pump Lifter Specifications Steering Clutch Booster Pump Suction Bell Support, Engine Front. s T Oil: By-pass Valve Coolers Filters Pan Pump Pump Suction Bell.. Operating Difficulties: Engine Coolant Overheating Engine Fuel System Engine Lubricating System Overheating, Coolant.. o Testing Temperature Regulators Thrust Bearing, Crankshaft Timing: Engine Gears Engine Valves Fuel Injection Timing Gear Housing Timing Gears Timing Marks Tolerances Turbocharger Turbocharger Lubrication Turbocharger Lubrication Valve Turbocharger Removal Pan, Oil Pistons Piston Pin Bearing Piston Rings Power Take-off Precombustion Chambers Pressure, Oil Gauge Pressure Ratio Control: Description Flushing Trouble-shooting Pump: Fuel: Drive Injection Transfer Oil Water Rack Setting Radiator Rear Power Take-off Regulator, Generator Regulators, Water Temperature p R Valve: Adjustment, Cylinder By-pass, Fuel By-pass, Oil Fuel Injection Guides Inspection and Reconditioning Lifters Operation Pressure Regulator, Oil Pump Rocker Arms Rotators Seat Specifications Timing Turbocharger Lubrication Valves and Valve Mechanism Vibration Damper Viscous Clutch (Fan Drivel Water: Directors Pump Seal Replacement Temperature Regulator Manifold V w

6 ENGINE SPECIFICATIONS A-IO Group 40. Page Permissible bearing clearance Bearing OD to housing bore Bearing ID to journal Inboard thrust bearing thickness Minimum thickness of inboard thrust washer Minimum thickness of outboard thrust washer Depth of thrust washer from face of plate Maximum depth of thrust washer from face of plate Minimum thickness of thrust ring Oil seal ring gap Oil seal ring width Oil seal ring groove width Permissible run out of rotating shaft (measured in vee blocks) Turbocharger (AiResearch T8) Torque on impeller housing bolts Torque on turbine housing bolts (5/6/) Torque on turbine housing bolts ( /8/) Torque on thrust plate retaining bolts Torque on impeller nut (see text) Turbocharger-to-manifold bolt torque using 9M70 Anti-Seize Compound Shaft end clearance Permissible shaft end clearance Bearing diameter (ID) Bearing diameter (OD)) Journal diameter Housing bore diameter Permissible Bearing Clearance: Bearing OD-to-housing bore Bearing ID-to-journal Inboard thrust bearing thickness Minimum thickness of inboard thrust bearing Depth of thrust washer from face of plate Maximum depth of thrust washer from face of plate Thrust collar thickness Minimum thrust collar thickness Oil seal ring gap Oil seal ring width Oil seal ring groove width Permissible run out of rotating shaft (measured in vee blocks) Valve Lifters Lifter diameter Bore diameter Permissible clearance Valves Exhaust valves: Clearance (hot) Stem clearance in guide Permissible clearance in guide Inlet valves: Clearance (hot) Stem clearance in guide Permissible clearance in guide.007 in..004 in in..089 in..090 in in..6 in..57in in in in..00 in lb. in lb. in lb. in lb. in. 0 lb. in lb. ft in..0 in in in in in..007 in..004 in in..089 in in..99 in in..98 in in in in..00 in in in..008 in..00 in in..009 in..08 in in..009 in. Valve and Valve Seat Specifications VALVE AND VALVE SEAT SPECIFICATIONS A-Valve seat angle. B-Valve guide length. C-Valve seat insert diameter. C.-Bore for valve seat insert. D-V,dve head diameter. E-Outside diameter of valve seat face (new), E,-Outside diameter of valve seal face [After reconditioning (MAX.n. F-Slem diameter. G-Valve guide bore. I-Valve lip thickness. K-Meaaurement from top of valve to face of head with valve aeated, L-Depth of bore for valve seat inserts. M-Valve seat width. T7.4, I X-Valve lace angle. INLET EXHAUST A 0 0 B 5.06" 5.06" C.5895" ".445" -.455" C,.586" -.587".4" -.4" D,500" -.50".45" -.55" E.457".0" E,.4" MAX..5" MAX. F.4950" ".4950" " kg.4985" ".5000" -.500" J. 40" MIN..4" MIN. K. 9" MIN. -.65" MAX..04" MIN. -.65" MAX. L.655" -.675".655" -.675" tm.07" MAX..07" MAX. X 9/4 9 /4 'Measure valve guide bore in portion of guide which is pressed into cylinder head closest to valve head. tlf valve seat face exceeds the maximum width after grinding. narrow the seat face by using a 5 stone or fly cutter. Valve Spring Outer: Pounds force When compressed to Inner: Pounds force When compressed to Valve Timing With valve clearances set correctly hot, dial indicator mounted above valve stem, readings taken with valve.075/ off its seat: Exhaust opens (Before bottom center) Exhaust closes (Before top center) Inlet opens (After top center) Inlet closes (After bottom center) Vibration Damper Bolt torque in in. 0-6' 00-5' 4 0-5' 4 0-0' 0-00 lb. ft.

7 ENGINE FUEL INJECTION EQUIPMENT A-IO Group 50. Page 5 6. Inspect and replace all damaged parts or gaskets. See the topic, SPECIFICATIONS, for checking wear of fuel rack bearing, camshaft journals and bearings. 7. If the camshaft bearings are being replaced, align the hole in the bearings with the oil passage in the housing and press the bearings into the bore of the housing. The bearing () is pressed in until the flange on the bearing is against the machined surface on the end of the pump housing. 8. Align the hole in the bearing (4) with the oil passage in the housing and press the bearing into the bore of the housing until it is 6 7/64" from the machined surface (6). 9. Align the hole in the bearing (5) with the oil passage in the housing and press the bearing into the bore of the housing until 7/6" of the bearing remains beyond flush of the machined surface (6) as shown. 0. If the rack bearings are replaced, the bearing (7) should be pressed into the housing until it is flush with the machined surface (6).. If the oil manifold () has been removed, make certain that the cross drilled holes in the injection pump camshaft housing line up with the drilled holes in the manifold. This will also make certain that the spray holes in the manifold are properly positioned under the lifter rollers.. Assemble the remaining parts in the reverse order of disassembly.. Tighten the nut (5) on the end of the camshaft to the specified torque value. See the topic, SPECIFICATIONS. 4. After lightening the nut (5) on the end of the camshaft, the width of the slot on the end of the camshaft should be.76" -.8". 5. After installing the fuel pump assembly on the engine and timing the pump camshaft, adjust the lifter settings. See the topic, FUEL PUMP LIFTER SETTING (ON ENGINE). FUEL PUMP LIFTER SETTING (ON ENGINE) If the injection pump lifters have been removed or disturbed from their original settings, it is necessary to reset them. The lifter settings should also be checked periodically and reset if necessary, to compensate for wear in the timing gears and pump lifters. If the lifter is too high, injection will begin early; if too low, injection will begin late. See the topic, FUEL INJECTION PUMP LIFTER YOKE AND PUMP PLUNGER INSPECTION. NOTE The maximum quantity of fuel that can be injected by each pump into the cylinder, and accordingly, the maximum horsepower output of the engine at a given operating speed is determined by the fuel rack setting. This rack setting should be changed only in accordance with information furnished Caterpillar dealers. See the topic, GOVERNOR ADJUSTMENTS. LOCATING TOP CENTER FLYWHEEL MARK The lifter settings can be set in the following manner: I. Turn the crankshaft in the direction of the engine rotation to "Top Center" (TC) on the compression stroke of the cylinder for which lifter is to be set. T Ul INSTALLATION OF CAMSHAFT AND RACK BEARINGS -Bearing. -0il manifold. 4-Bearing. IS-Bearing. IS-Machined face. 7-Fuel rack bearing. 7. If the "Top Center" mark on the flywheel is turned past the pointer, turn the flywheel backward approximately 60 0 Then turn the crankshaft again in the direction of crankshaft rotation until the "Top Center" mark aligns with the pointer.

8 A-0 Group 0. Page STARTING ENGINE TABLE OF CONTENTS Section Index A-0 Specifications A-0 Operation 8A-0 Removal and Installation A-0 Lubrication System 8A-0 Group Fuel System... la-0 00 Cylinder Head and Valves A-0 Cylinder Head and Valves (Later).... A-0 Pistons, Rings and Connecting Rods.... 8A-0 Pistons, Rings and Connecting Rods (Later)... A-0 Timing Gear Housing A-0 Magneto (Wico) A-0 Crankshaft, Flywheel and Main Bearings.. 8A-0 Crankshaft, Flywheel and Main Bearings (Later) 5A-0 Camshaft 8A-0 Camshaft (Later) 5A-0 Starting Mechanism A-0 lid

9 A-0 Group 0. Page ST ARTING ENGINE INDEX A L Adjustments: Carburetor Governor Starter Pinion Latch Valve Clearance Latch, Starter Pinion Lifters, Valve Lubricating System M Bearings: Connecting Rod Main Piston Pin Brackets, Support Camshaft Carburetor Clearances and Tolerances Clutch Clutch Housing Connecting Rod Bearings Cooling Crank Mechanism, Hand Crankshaft Crankshaft Gear Cylinder Head Cylinders B C D Magneto Drive Main Bearings Oil: Pan Pump Pump Pressure Regulating Valve Operation, Starting Engine Pan, Oil Pinion, Starter Pistons Piston Pin Bearings Pressure Regulating Valve Pump, Oil Reboring Cylinders Removing Engine Rings, Piston o P R Data, Engine Drive, Magneto 40-0 S Flywheel Fuel System Gear: Camshaft Crankshaft Oil Pump Transmission Governor Guides, Valve F G Screen, Sump Specifications: Cylinder Reboring General Springs: Governor Valve Starter Pinion Starting Mechanism Timing Gear Housing Tolerances Transmission T Hand Crank Mechanism Head, Cylinder Housing: Clutch and Transmission Timing Gear H Valve: Clearance Adjustment Guides Lifters Pressure Regulating V

10 Group 5 Page 4 A-0 STARTING ENGINE MAGNETO (WICO) Assembly. Make certain all parts are clean. Apply ball and roller bearing lubricant between the turns of the impulse spring.. Press drive flange () on the rotor shaft. NOTE Make certain an undamaged oil slinger is in place, before the drive flange is installed. f474 PREPARING TO DISASSEMBLE IMPULSE DRIVE COUPLING I-Locknut. -Drive cup. -Rotor shaft.. Install trip arm () and the trip arm spring.. Mark the direction of the drive spring spiral in drive cup () and remove the spring. NOTE The spiral of the spring will wind in the wrong direction if the spring is installed incorrectly. 4. Mark pin (4) to allow the trip arm to be installed on the correct pin. IMPULSE DRIVE COUPLING ASSEMBLY I-Drive flange. -Trip arm. -Spacer. 4-Plate. 5-Washer. 6-Drive cup spacers. 7-Drive cup. a-locknut. 4. Install spacer (), plate (4), washer (5) and drive cup spacers (6). n05 PREPARING TO REMOVE TRIP ARM 4-Pin. 5-Trip arm spring. 6-Trip arm. 7-Drive flange. NOTE If only drive cup () and trip arm (6) are to be removed, it is not necessary to remove the rotor from the magneto housing. Block or hold drive cup () to prevent it from turning and loosen locknut (). Proceed with Steps through Press drive flange (7) from the rotor shaft. NOTE When an arbor press is used to remove drive flange (7), the oil slinger is usually damaged and a new one must be installed. 5. Install drive cup (7) by first pulling the inner eye of the drive spring one turn out of the drive cup. Next place the cup on the rotor shaft and latch the inner eye of the spring in the notches in the drive cup spacers (6). Push the drive cup a short distance on the shaft and turn the cup one full turn (to wind up the drive spring). Push the drive cup (7) in place to engage the drive flange (). 6. Install locknut (8) and stake it in two places to lock the nut on the shaft. BEARING REMOVAL A replaceable bearing is located in a bearing assembly on the rotor shaft between the magneto drive and the rotor magnet. The rotor must be removed from the magneto housing and the drive (either an impulse drive coupling or a driving lug) removed before the bearing assembly can be removed from the rotor shaft. See covering topics. NOTE The seal must be installed with the lip facing the magneto drive.

11 9B-0 Group 0 Page I POWER TRANSMISSION UNITS TABLE OF CONTENTS Section Group Index B-0 0 Specifications 9B-0 40 Hydraulic Control System, Testing and Adjusting 7B-0 4 Introduction 9B-0 65 Universal Joint... 9B-0 70 Torque Divider Removal 9B-0 90 Torque Divider 7B Transmission Hydraulic Control 9B-0 05 Trouble Shooting Guide 7B-0 8 Transmission Removal 9B-0 9 Transmission... 9B-0 0 Transmission Lubrication System 9B-0 0 Bevel Gear 9B-0 40 Hydraulic System 9B-0 45 Brakes B-0 50 Steering Clutches 9B-0 60 Steering Clutch Hydraulic Control 9B-0 70 Final Drive... 9B-0

12 9B-o Group 0 Page POWER TRANSMISSION UNITS INDEX Adjustments: Bevel Gear Backlash Bevel Gear Bearing Bevel Gear and Pinion Setting Brake, Steering Clutch Final Drive Hydraulic Control System Testing and Adjustment Transmission Hydraulic Control Linkage A Group Page Hydraulic Pump Hydraulic System Introduction, Power Shift Group Page B Joint, Universal 70 - I Bevel Gear Bevel Gear and Pinion Setting Brakes, Steering Clutch C 40 I Lubrication: Final Drive Torque Divider Transmission L Checking Hydraulic Control Pressure Clearances and Tolerances Clutch Designation Clutches, Steering Clutches, Transmission Controls, Steering Clutch Hydraulic Controls, Transmission Hydraulic Data Divider Lubrication, Torque Divider, Torque Drive, Final Filter, Oil Final Drive Bearing Adjustment Gear Pinion Sprocket Sprocket Shaft Flow Control Valve Flow Divider Gear: Bevel Final Drive Guide, Trouble Shooting D F G H I I IS I Metal Floating Ring Seals Oil Filter Oil Pump: Final Drive Steering Clutch Hydraulic Control Operation: Brakes Hydraulic System Steering Clutches Steering Clutch Hydraulic Controls Torque Divider Transmission Transmission Hydraulic Controls Hydraulic Pump Salety Valve Pinion, Final Drive Planet Carrier (Torque Divider) Planet Carrier (Transmission) Pressure Control Valve Pressure Reliel Valve: Brake Steering Clutch Hydraulic Control Pumps: Final Drive Oil Hydraulic Torque Divider Scavenge M o p ISO 45 - I I Hydraulic Booster, Brake Hydraulic Control Safety Valve Hydraulic Control. Steering Clutch Hydraulic Control System Testing and Adjustment Hydraulic Controls, Transmission I Salety and Directional Valve Seal, Final Drive Metal Floating Ring Specifications, Tolerances and Clearances Speed Selector Valve s

13 Group 0 Page 9B-0 POWER TRANSMISSION UNITS INDEX Sprocket, Final Drive Sprocket Shaft, Final Drive Steering Clutch Steering Clutch Brake Steering Clutch Hydraulic Control System, Hydraulic Testing and Adjustment, Hydraulic Control System Torque Divider Torque Divider Lubrication Torque Divider Removal Transmission Clutches No. Carrier Hydraulic Controls Input Shaft T Group Page - 9 Lubrication..., Output Shaft No. Carrier Removal 70 Trouble Shooting Guide 45 U Universal Joint... 4 I V 00. Valve: Flow Control and Relief 90 Flow Divider... 0 Pressure Control 0-5 Safety and Directional Speed Selector 0-9 Steering Clutch Hydraulic Control Relief 05 - Torque Converter Inlet Relief 0-5 Torque Converter Outlet Relief 0 7 Transmission Lubrication Regulator.... Group Page

14 9B-40 Group 0 Page TRACK ROLLER FRAME TABLE OF CONTENTS Section Group Index 9B Specifications 9B Tracks 9B - 40 Track Carrier Rollers and Track Rollers. 9B Front Idler and Recoil Spring 9B Equalizer Bar 9B Track Roller Frame Removal 9B

15 9B-40 Group 0 Page TRACK ROLLER FRAME INDEX Adjustments: Front Idler Track Track Adjusting Mechanism A Group Page Track Carrier Roller 90 - Bar, Equalizer.... Bushings, Track Pins and.... Carrier Rollers, Track Clearances and Tolerances Equalizer Bar B C E F Frame Removal, Track Roller Front Idler Idler, Front Installing Track Links, Track Lubrication: Front Idler Track Carrier Rollers Track Rollers L Master Pin Mechanism, Track Adjusting Metal Floating Ring Seal Installation Pins and Bushings, Track Recoil Spring Rollers: Carrier, Track Track Roller Frame Removal, Track Separating Track SpeCifications Spring: Recoil Tracks Track: Adjusting Adjusting Mechanism Carrier Rollers Installing Links Pins and Bushings Rollers Separating Track Roller Frame Removal M P R s T Group Page

16 9B-00 Group 0 Page SEAT, FUEL TANK AND MISCELLANEOUS TABLE OF CONTENTS Section Group Seat and Seat Frame Removal 9B Fuel Tank Removal 9B Dash and Control Support Removal. 9B Hood and Radiator Cover. 9B Floor Plate Removal 9B Drawbar Removal and Installation. 9B

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